Can Am Outlander Gen 2 - The Ultimate Diyer'S Maintenance And Mod

Let’s be honest, there’s a special kind of pride that comes from owning and maintaining a beast like the can am outlander gen 2. You know the feeling—the roar of that Rotax V-Twin, the confidence it gives you on gnarly trails, and the satisfaction of knowing you keep it running like a top. But keeping it in peak condition can feel daunting if you don’t know where to start.

We promise this comprehensive guide will change that. We’re here to pull back the curtain and give you the confidence to tackle everything from basic pre-ride checks to diagnosing those annoying trail-side issues yourself.

In this ultimate can am outlander gen 2 guide, we’ll break down exactly what makes this platform a legend, walk you through a bulletproof maintenance routine, troubleshoot common problems, and even explore the best mods to make your machine truly your own. Let’s get those hands dirty.

What Makes the Can-Am Outlander Gen 2 a Trail Legend?

First, what exactly are we talking about when we say “Gen 2”? BRP (Bombardier Recreational Products) introduced the second-generation, or G2, platform around the 2012 model year, and it was a game-changer. This wasn’t just a facelift; it was a fundamental redesign from the ground up.

The heart of this evolution is the revolutionary SST G2 (Surrounding Spar Technology) frame. Unlike traditional tube frames, the G2 uses a massive, single-spar steel frame that provides incredible strength and rigidity while also improving rider comfort and handling precision. It’s the backbone that makes this machine so capable.

Key Benefits of Can-Am Outlander Gen 2 Engineering

The G2 platform brought a host of upgrades that riders still rave about today. Understanding these benefits helps you appreciate what you’re working on.

Improved Handling and Stability: The stiffer G2 frame, combined with a revised Torsional Trailing arm Independent (TTI) rear suspension, keeps the machine planted and predictable, even in rough terrain.
Enhanced Rider Comfort: The new geometry was designed to reduce rider fatigue on long days. You feel more in control and less beat up after a full day of riding.
Unmatched Rotax Power: The Gen 2 models feature the legendary Rotax V-Twin engines (from 500cc to 1000cc), known for their stump-pulling torque and reliability.
DIY-Friendly Design: While complex, many key components are more accessible than on previous models, making routine maintenance more straightforward for the weekend mechanic.

Your Essential Can-Am Outlander Gen 2 Care Guide

An ounce of prevention is worth a pound of cure, especially when you’re miles from the trailhead. A solid maintenance routine is the single best way to ensure your Outlander is always ready to ride. This is where you’ll find the best can am outlander gen 2 best practices.

The 5-Minute Pre-Ride Inspection

Before every single ride, take five minutes to perform a quick walk-around. It’s the cheapest insurance you can get. Think of it like T-CLOCS, a system motorcyclists use, but adapted for your ATV.

Tires & Wheels: Check tire pressure—running too low or too high can ruin handling and cause damage. Eyeball the sidewalls for cuts and check that lug nuts are tight.
Controls & Cables: Squeeze the brake levers; they should feel firm, not spongy. Test the throttle for smooth operation (it should snap back when released). Check the 4×4 switch.
Lights & Electrics: Turn the key on. Test your headlights (high and low beam), taillights, and brake lights. A flickering light could signal a loose connection.
Oil & Fluids: Pull the engine oil dipstick and check the level. Glance at the coolant overflow bottle and the brake fluid reservoirs. Look for any drips on the floor under the machine.
Chassis & Suspension: Grab the racks and tires and give them a good shake. You’re looking for excessive play in wheel bearings, A-arm bushings, or tie rod ends.

Key Maintenance Intervals You Can’t Ignore

Your owner’s manual is the ultimate authority, but here are the big jobs you can tackle in your own garage.

Engine Oil & Filter Change: This is non-negotiable. Use a quality synthetic oil like XPS 5W-40 and a genuine BRP or high-quality aftermarket filter. You’ll need a drain pan, the correct size socket for the drain plug, and an oil filter wrench. Pro Tip: Warm the engine for a few minutes before draining to help the oil flow out faster.

Air Filter Service: Your Outlander’s engine breathes through this filter. In dusty conditions, check it after every ride. Tap out loose dust, and if it’s a reusable foam filter, wash it with filter cleaner, let it dry completely, and re-oil it properly. A clogged filter kills performance.

Drivetrain Fluids: Your front and rear differentials and gearbox have their own oil. These fluids break down over time. Changing them is a simple drain-and-fill job that prevents costly gear and bearing failures down the road.

Troubleshooting Common Problems with Can-Am Outlander Gen 2 Models

Even the best-maintained machines have bad days. Knowing what to look for can turn a weekend-ruining breakdown into a simple fix. Here are some of the most common problems with can am outlander gen 2 quads and how to diagnose them.

The Dreaded “No-Start” Situation

You turn the key and… nothing. Don’t panic. Run through this checklist first.

The Battery: This is the culprit 90% of the time. Are the terminals clean and tight? Use a multimeter to check the voltage; a healthy battery should read 12.6V or more. If it’s below 12.2V, it needs a charge.
Safety Switches: Is the machine in Park or Neutral? Are you holding the brake lever? The Gen 2 has safety interlocks that can prevent starting if these aren’t engaged. Check your tether cord switch, too.
Fuel and Spark: When you turn the key, can you hear the faint whirr of the fuel pump priming for a couple of seconds? If not, check the fuel pump fuse. If you suspect no spark, a simple inline spark tester is a great tool to have.

Overheating on the Trail

The temperature light is flashing, and you’re losing power. Pull over safely and shut it down immediately. Never open a hot radiator cap.

First, look at your radiator. Is it caked in mud? This is the most common cause. Wait for everything to cool down, then use a gentle stream of water (not a pressure washer, which can bend the delicate fins) to clean it out from the back towards the front.

If the radiator is clean, check your coolant level in the overflow bottle. If it’s low, you may have a leak. Also, listen to see if your radiator fan is kicking on as it should. If not, the fuse, relay, or fan motor itself could be the issue.

Annoying Drivetrain Clicks, Pops, and Grinds

Strange noises are your ATV’s way of telling you something is wrong. Listen closely.

A rhythmic clicking when turning: This is the classic sign of a failing CV axle. Inspect the rubber CV boots for tears. If a boot is torn, dirt and water have gotten in and destroyed the joint.
A grinding or squealing tied to wheel speed: This often points to a bad wheel bearing or worn-out brake pads. Safely jack up the corner and try to wiggle the wheel top-to-bottom and side-to-side. Any significant play means the bearing is shot.
A clunking sound over bumps: This is typically caused by worn-out A-arm bushings. Have a buddy rock the machine while you look closely at the pivot points for movement.

How to Can-Am Outlander Gen 2: Smart Mods for Every Rider

One of the best parts of owning an Outlander is making it your own. But it’s easy to get carried away. Here’s a practical approach to modifications that deliver real results.

Stage 1: The “Must-Have” Upgrades

These are the mods we recommend for almost every Gen 2 owner.

Tires: The single best upgrade you can make. The stock tires are a compromise. Choosing a tire for your specific terrain—like ITP Mud Lites for mud or Maxxis Bighorns for all-around trail riding—will transform your machine’s handling and capability.

Full Skid Plate: The factory plastic protection is minimal. A full aluminum or, even better, a UHMW (Ultra-High Molecular Weight plastic) skid plate set from a brand like Ricochet or Iron Baltic will protect your frame, engine, and differentials from rocks and stumps that can end your day.

Winch: Don’t go into the woods without one. A 2500lb or 3500lb winch from a reputable brand like Warn or Superwinch is a crucial piece of recovery gear for you and your riding buddies.

Stage 2: Performance and Utility Enhancements

Once you have the basics covered, you can start tailoring the machine to your needs.

Clutch Kit: If you’ve added bigger, heavier tires, a clutch kit is essential. It recalibrates your CVT to account for the extra mass, restoring lost acceleration and preventing premature belt wear. Brands like Dalton and EPI offer excellent kits.

Lighting: Upgrading to LED headlights or adding an LED light bar makes a world of difference for night riding, increasing both safety and confidence.

Sustainable Can-Am Outlander Gen 2 Best Practices

Being a true enthusiast means respecting the machine and the environment we ride in. A few conscious choices can make a big impact, and these eco-friendly can am outlander gen 2 tips are easy to adopt.

Eco-Friendly Maintenance

Your responsibility doesn’t end when the maintenance is done. Always dispose of used oil, coolant, and other fluids at a certified auto parts store or local recycling center. Never dump them on the ground or down a drain.

When washing your rig after a muddy ride, use a biodegradable soap and, if possible, wash it on a grassy area away from storm drains or waterways to prevent runoff.

Riding with Respect

The best way to ensure our trails stay open for years to come is to practice responsible riding. This means adhering to the principles of organizations like Tread Lightly!.

Travel Responsibly: Stay on designated trails and routes.
Respect the Rights of Others: This includes other riders, hikers, and property owners.
Educate Yourself: Know the local regulations before you go.
Avoid Sensitive Areas: Steer clear of wetlands, meadows, and historical sites.
Do Your Part: Pack out everything you pack in.

Frequently Asked Questions About the Can-Am Outlander Gen 2

What years are the Can-Am Outlander Gen 2?

The Can-Am Outlander G2 platform was introduced for the 2012 model year for the 800R and 1000 models. The mid-cc models (500/650) transitioned to the G2 frame in the following years. It remains the basis for the modern Outlander platform.

What is the best oil for a Can-Am Outlander Gen 2?

BRP recommends its own XPS 5W-40 4-stroke synthetic blend oil. However, any high-quality, wet-clutch compatible (JASO MA/MA2) synthetic 5W-40 ATV/motorcycle oil from a reputable brand will work well. The key is regular changes.

How often should I check my CVT belt?

It’s good practice to inspect your CVT belt for glazing, cracking, or excessive wear every 50-100 hours of riding, depending on your riding style. If you do a lot of slow, technical rock crawling or mud bogging, check it more frequently as that type of riding is very hard on belts.

The best of all the can am outlander gen 2 tips is to always carry a spare belt and the simple tools needed to change it on the trail. It can save you from a very long walk home.

The Can-Am Outlander Gen 2 is more than just an ATV; it’s a passport to adventure. It’s a robust, powerful, and incredibly capable platform that, with the right care and attention, will provide years of reliable fun. By embracing the DIY spirit and arming yourself with knowledge, you’re not just a rider—you’re the master of your machine.

Now, get in the garage, check those fluids, and plan your next ride. Stay safe, get dirty, and enjoy every minute of it!

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Thomas Corle

Founder & Automobile expert at FatBoysOffroad

Automobile expert and off-road enthusiast, sharing in-depth knowledge of vehicles, gear, and adventures. Helping readers make smart decisions and enjoy the thrill of off-roading safely and confidently.